Project Scope

Design, supply, installation, and commissioning of a PLC & SCADA based Automatic Temperature Control System for two vessels.

Background:

The customer is a leading manufacturer of quality propellants for various types of ammunition, including 105mm, 120mm, naval ammunition, and small arms. The factory’s production plant comprises multiple vessels using water jackets to regulate temperature by adjusting the water flow through manual valves. The manual system faced several challenges, including unpredictable temperature variations, safety risks, and lack of historical data.

To address these issues, FAIZAL proposed an Automatic Temperature Control System utilizing PLC (Programmable Logic Controller), SCADA (Supervisory Control and Data Acquisition), field sensors, and automated field actuators for two vessels at the manufacturing facility. This system allows operators to easily set temperature points and start the process from the SCADA interface. The system takes temperature feedback from field sensors and automatically adjusts the hot and cold water valves using PID (Proportional-Integral-Derivative) control logic within the PLC.

System Description:

The proposed system ensures precise temperature control within the vessels through the controlled circulation of hot and cold water. Key components and functionalities include:

• Temperature Measurement: Thermocouples measure the temperature inside the vessels. These readings are transmitted to the PLC via temperature transmitters.
• PID Control: The PLC utilizes a PID algorithm to maintain the desired process temperature. Based on the temperature feedback, the PID output adjusts the pneumatic control valves to regulate the flow of hot and cold water, thereby raising or lowering the temperature inside the vessels.
• Emergency Bypass Valve: A bypass valve is included to handle emergency situations, ensuring safety and continuous operation.
• SCADA Integration: The PLC is integrated with a SCADA system, allowing real-time monitoring and control. The SCADA interface displays the temperatures of both vessels, motor direction, motor power consumption, machine idle time, operator caution alarms, auto mode failure, high-temperature alarm, safety alarm, and safety shutdown alarm.
• User Interaction: Operators can select different operating modes for various propellants from the SCADA screen and set temperature points. The system’s user-friendly interface facilitates easy operation and enhances process efficiency.
• Data Historization: SCADA records and stores historical data in its database, providing valuable insights for future reference and process optimization.

Benefits:

• Enhanced Safety: Automated control reduces the risk of accidents associated with manual temperature regulation.
• Improved Accuracy: The PID control algorithm ensures precise temperature maintenance, enhancing product quality.
• Operational Efficiency: Automation streamlines the temperature control process, reducing manual intervention and associated errors.
• Real-Time Monitoring: The SCADA system provides real-time data visualization, allowing operators to make informed decisions promptly.
• Historical Data Analysis: Data historization enables trend analysis and process optimization, contributing to continuous improvement.

Conclusion:

The implementation of the PLC & SCADA based Automatic Temperature Control System for the two vessels at the propellant manufacturing facility has significantly improved safety, accuracy, and efficiency. By automating the temperature control process and integrating it with a sophisticated monitoring system, FAIZAL has provided the customer with a reliable and expandable solution for their critical manufacturing operations.